Badger Meter ER-500 Programming Manual

Display

ER-500 Advanced

DSY-PM-00028-EN-02 (February 2017)

Programming Manual

ER-500 Flow Monitor

Page ii February 2017DSY-PM-00028-EN-02

Programming Manual

CONTENTS

Scope of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Terminology and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Connecting the ER-500 Monitor to a Pulse Output Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Transmitter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Operating The Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Programming Using Frequency Output Flow Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Standard ER-500, Rate SU is Set to Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Advanced ER-500, Basic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Standard ER-500, Rate SU is Set to Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Advanced ER-500, Advanced Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

K-factors Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Modbus Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Modbus Register / Word Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Register Mappings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Control Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Page iii February 2017 DSY-PM-00028-EN-02

ER-500 Flow Monitor

Page iv February 2017DSY-PM-00028-EN-02

Scope of This Manual

SCOPE OF THIS MANUAL

This manual is intended to help you get the ER-500 flow monitor up and running quickly.

MPORTANTI

Read this manual carefully before attempting any installation or operation. Keep the manual accessible for future reference.

UNPACKING AND INSPECTION

Upon opening the shipping container, visually inspect the product and applicable accessories for any physical damage such
as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment.

OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the

carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.

SAFETY

Terminology and Symbols

Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing death or
serious personal injury.

Indicates a hazardous situation, which, if not avoided, could result in severe personal injury or death.

Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing minor or
moderate personal injury or damage to property.

Considerations

The installation of the ER-500 flow monitor must comply with all applicable federal, state, and local rules, regulations,
and codes.

WARNING

EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.

AVERTISSMENT

RISQUE D’EXPLOSION - LA SUBSTITUTION DE COMPOSANTS PEUT RENDRE CEMATÉRIEL INACCCEPTABLE POUR LES
EMPLACEMENTS DE CLASSE I, DIVISION 2.

WARNING

DO NOT CONNECT OR DISCONNECT EITHER POWER OR OUTPUTS UNLESS THE AREA IS KNOWN TO BE
NON-HAZARDOUS.

AVERTISSMENT

RISQUE D’EXPLOSION. NE PAS DÉBRANCHER TANT QUE LE CIRCUIT EST SOUSTENSION, À MOINS QU’LL NE S’AGISSE
D’UN EMPLACEMENT NON DANGEREUX.

MPORTANTI

Not following instructions properly may impair safety of equipment and/or personnel.

Electrical Symbols

Function Direct Current Alternating Current Earth (Ground) Protective Ground Chassis Ground

Symbol

DSY-PM-00028-EN-02 Page 5 February 2017

Introduction

INTRODUCTION

The ER-500 flow monitor incorporates state-of-the-art digital signal processing technology designed to provide the user with
exceptional flexibility at a very affordable price. Though designed for use with Badger Meter® flow sensors, this monitor can
be used with almost any flow sensor producing a low amplitude AC output or contact closure signal.

The ER-500 monitor uses contact closures from an ILR transmitter that translates to flow rate through the use of a scaling
constant called a K-factor.

This monitor is also capable of accepting low-level frequency input signals typically found in flow sensors that generate
a frequency output. The output signal for these type of sensors is a frequency proportional to the rate of flow. The ER-500
monitor uses the frequency information to calculate flow rate and total flow. If required, the flow monitor can easily be
re-configured in the field.

J1

KB/Display

P2

+ –

RS485 Gnd

Setpoint 1

Setpoint 2

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

Freq. In

4-20mA

TR_B

TR_A

Gnd

P1

2

1

+

–

+

–

+

–

JP1

Input Total Pulse Signal

Pulse

Mag

JP2

OC

Iso

JP3

High

Low

TB1

Figure 1: ER-500 monitor

The monitor is available in two different levels of functionality. The standard model provides all the functions necessary for
the most common flow metering applications. The advanced version adds communications capabilities over an RS485 bus
using Modbus RTU and control outputs.

DSY-PM-00028-EN-02Page 6 February 2017

(Should be set to Low for IOG Meter)

Auxiliary Reed

Installation

INSTALLATION

Connecting the ER-500 Monitor to a Pulse Output Device

The ER-500 monitor has two jumpers that are used to set the type of signal and the minimum amplitude of the signal that
it accepts. When used with Badger Meter IOG oval gear meters, the Input Signal Level should be set to Low and the Input
Waveform should be set for pulse as shown in Figure 2.

JP1

Pulse

Mag

OC

Iso

High

Low

Input Total Pulse Signal

Input Waveform Selection

(Should be set to Pulse for IOG meter)

JP2

JP3

Input Signal Level Selection

Figure 2: Input jumper settings

If the ER-500 monitor is a replacement, it must be calibrated for the IOG it is intended to be used with. The K-factor for the
specific IOG meter must be programmed into the ER-500 monitor. The K-factor value is found on the calibration certificate
that came with the IOG meter. For instructions on programming the K-factor, see Enter Flow Sensor's K-factor* on page 17.

Transmitter Connections

The ILR transmitter typically used with the IOG meter family has two sets of pulse output wires. The white and green output
leads connected to the primary reed switch bank are generally the first choice (see Figure 3).

TR_B

RS485 Gnd

Setpoint 1

Setpoint 2

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

TR_A

Freq. In

4-20mA

Reed Switch

Bank

Switch Bank

ILR

Pulse Transmitter

White

Green

Blue

Black

Figure 3: Typical IOG meter input connection

The ILR transmitter also has a secondary (auxiliary) set of pulse output wires. Either pair can be used to connect to the ER-500
monitor. The connections are:

P1

Gnd

Gnd

+

JP1

Input Total Pulse Signal

Pulse

–

Mag

+

JP2

–

OC

+

Iso

–

JP3

High

Low

TB1

Freq. In

+

–

Pulse

Mag

ILR Wires

ER-500 Terminals Reed Switch Bank (Primary) Reed Switch Bank (Auxiliary)

Freq. In + White Blue

Freq. In - Green Black

DSY-PM-00028-EN-02 Page 7 February 2017

10

Installation

Power Connections

The ER-500 monitor has two power supply options. The first power supply is an internal lithium 3.6V DC D size cell that powers
the monitor for about six years when no outputs are used. The monitor can also be powered by a 4…20 mA current loop.
See Figure 4. If the current loop is used, a sensing circuit within the monitor detects the presence of the current loop and
automatically disconnects the battery from the circuit.

TR_B

Pulse

Mag

OC

Iso

High

Low

P1

JP1

Input Total Pulse Signal

JP2

JP3

…28V DC

4-20 mA

Current Loop

(10 …28V DC)

Load

RS485 Gnd

Setpoint 1

Setpoint 2

Freq. In

4-20mA

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

TR_A

Gnd

+

–

+

–

+

–

TB1

Figure 4: Loop power connections

DSY-PM-00028-EN-02Page 8 February 2017

OPERATING THE MONITOR

Figure 5: Keypad detail

Buttons

MENU Switches between RUN and PROGRAMMING modes

Operating The Monitor

2

1

Scrolls backwards through the parameter options, increments numeric variables and scrolls backward through

UP

parameters

RIGHT

ENTER Saves programming information, advances to the next programming parameter, and used in the reset process

Scrolls forward through the parameter options, moves the active digit to the right and scrolls forward through
parameters

Special Functions

MENU + ENTER Simultaneously press and hold to reset the current totalizer

MENU Press and hold for three seconds to enter Extended Programming mode

UP+ RIGHT Simultaneously press and hold to show the firmware version number, then the grand total

Modes

RUN Normal operating mode
PROGRAM Used to program parameters in the display
EXTENDED PROGRAMMING Used to program advanced variables into the display
TEST Used as a diagnostic tool to show input frequency and totalizer counts

If the monitor is a replacement, the K-factor of the flow sensor has changed, or the monitor is being used with some other
pulse generating device, programming is necessary.

Programming Using Frequency Output Flow Sensors

Each Badger Meter flow sensor is shipped with either a K-factor value or frequency data. If frequency data is provided, the
data must be converted to a K-factor before programming the monitor. The K-factor represents the number of pulses per
unit of volume. See Connecting the ER-500 Monitor to a Pulse Output Device on page 7. The K-factor is needed to program
the monitor.

DSY-PM-00028-EN-02 Page 9 February 2017

Rate SU

(Rate Unit Setup)

Simple Advanced

Menu Structure

MENU STRUCTURE

Standard ER-500, Rate SU is Set to Simple

Shape Key

Basic Menu

Extended Menu

Sub Menu

START

KFacUnt

(K-Factor Unit)

Pul/Gal

Pul/m³
Pul/Ltr
Pul/Ft³

=

Pulses/Gallon

=

Pulses/meter³

=

Pulses/Liter

=

Pulses/Ft³

KFactor

(K-Factor Value)

Numeric Entry

Flo Unt

(Rate/Total Units)

GPM

=

Gallons/Min

Gal

=

Gallons

OB/D

=

Oil Barrel/Day

BBL

=

Barrels

m³/D

=

Meters³/Day

m³

=

Meters³

m³/H

=

Meters³/Hour

m³

=

Meters³

LPM

=

Liters/Min

Ltr

=

Liters

PulsOut

(Pulse Output)

Disable

Enable

Fl=20mA

(Flow at 20 mA)

Numeric Entry

Clr G-T

(Clear Grand Total)

NO

YES

Passwd

(Password)

Numeric Entry

RstPswd

(Reset Password)

Numeric Entry

DSY-PM-00028-EN-02Page 10 February 2017

Advanced ER-500, Basic Menu

Menu Structure

Shape Key

Basic Menu

Extended Menu

Sub Menu

START

KFacUnt

(K-Factor Unit)

Pul/Gal

Pul/m³
Pul/Ltr
Pul/Ft³

=

Pulses/Gallon

=

Pulses/meter³

=

Pulses/Liter

=

Pulses/Ft³

KFactor

(K-Factor Value)

Numeric Entry

RateInt

(Rate time interval)

=

Sec

Second

=

Min

Hour

Day

Minute

=

Hour

=

Day

RateUnt

(Unit/interval=T)

GPT

=

Gallons/T

LB/T

=

Liquor Barrel/T

OB/T

=

Oil Barrel/T

AF/T

=

Acre Feet/T

ML/T

=

Million Liters/T

LPT

=

Liters/T

m³/T

=

Meters³/T

Ft³/T

=

Feet³/T

MG/T

=

Million
Gallons/T

MASS

Kg/T

=

Kilograms/T

Lb/T

=

Pounds/T

TotalUnt

(Totalizer Unit)

Gal

=

Gallons

LBL

=

Liquor Barrel

OBL

=

Oil Barrel

AFt

=

Acre Feet

MLt

=

Million Liters

LPT

=

Liters

m³

=

Meters³

Ft³

=

Feet³

MGa

=

Million
Gallons

MASS

Kgs

=

Kilograms

Lbs

=

Pounds

TotlMult

(Totalizer Multiplier)

× 1000

×100

×10

0.1

0.01

1

=

× 100

=

× 10

=

× 1

=

× 0.1

=

× 0.01

=

×1000

Spec Gr

(Specic Gravity)

Numeric Entry

PulsOut

(Pulse Output)

Disable

Enable

Fl=20mA

(Flow at 20 mA)

Numeric Entry

Clr G-T

(Clear Grand Total)

NO

YES

Passwd

(Password)

Numeric Entry

Menu item appears

only when MASS

units are selected.

DSY-PM-00028-EN-02 Page 11 February 2017

RstPswd

(Reset Password)

Numeric Entry

Rate SU

(Rate Unit Setup)

Simple Advanced

Menu Structure

Standard ER-500, Rate SU is Set to Advanced

Shape Key

Basic Menu

Extended Menu

Sub Menu

START

Display (Options)

Flow

Flow GT = Grand Total

Test

KFacUnt

(K-Factor Unit)

Pul/Gal

Pul/m³
Pul/Ltr
Pul/Ft³

=

Pulses/Gallon

=

Pulses/meter³

=

Pulses/Liter

=

Pulses/Ft³

KFactor

(K-Factor Value)

Numeric Entry

RateInt

(Rate time interval)

=

Sec

Second

=

Min

Minute

=

Hour

Day

=

Hour
Day

RateUnt

(Unit/interval=T)

GPT

=

Gallons/T

LB/T

=

Liquor Barrel/T

OB/T

=

Oil Barrel/T

AF/T

=

Acre Feet/T

ML/T

=

Million Liters/T

LPT

=

Liters/T

m³/T

=

Meters³/T

Ft³/T

=

Feet³/T

MG/T

=

Million
Gallons/T

MASS

Kg/T

=

Kilograms/T

Lb/T

=

Pounds/T

TotalUnt

(Totalizer Unit)

Gal

=

Gallons

LBL

=

Liquor Barrel

OBL

=

Oil Barrel

AFt

=

Acre Feet

MLt

=

Million Liters

LPT

=

Liters

m³

=

Meters³

Ft³

=

Feet³

MGa

=

Million
Gallons

MASS

Kgs

=

Kilograms

Lbs

=

Pounds

TotlMult

(Totalizer Multiplier)

× 1000

×100

×10

0.1

0.01

1

=

× 100

=

× 10

=

× 1

=

× 0.1

=

× 0.01

=

×1000

Spec Gr

(Specic Gravity)

Numeric Entry

Scale F

(Scale Factor)

Numeric Entry

SetTotl

(Set Total Value)

Numeric Entry

Cuto

(Low Flow Cuto)

Numeric Entry

Damping

(Display Damping)

Numeric Entry

Continued on

next page.

Menu item appears

only when MASS

units are selected.

DSY-PM-00028-EN-02Page 12 February 2017

Standard ER-500, Rate SU is Set to Advanced (continued)

Continued from

previous page.

Menu Structure

PulsOut

(Pulse Output)

Disable

Enable

Fl=20mA

(Flow at 20 mA)

Numeric Entry

4-20Cal

(Calibrate 4-20)

NO

YES

4mA Out

(4 mA Output)

Numeric Entry

20mA Out

(20 mA Output)

Numeric Entry

4-20Tst

(4-20 mA Output)

Numeric Entry

Linear

(Linearization)

Lin Pts = Linear Points (2 to10)

Numeric Entry

Clr G-T

(Clear Grand Total)

NO

YES

Passwd

(Password)

Numeric Entry

RstPswd

(Reset Password)

Numeric Entry

Freq#1

(Frequency 1)

Numeric Entry

Coef#1

(Coecient 1)

Numeric Entry

Freq#(x)

(Frequency 2-10)

Numeric Entry

Coef#(x)

(Coecent 2-10)

Numeric Entry

DSY-PM-00028-EN-02 Page 13 February 2017

Menu Structure

Advanced ER-500, Advanced Menu

Shape Key

Basic Menu

Extended Menu

Sub Menu

START

Display (Options)

Flow

Flow GT = Grand Total

Test

KFacUnt

(K-Factor Unit)

Pul/Gal

Pul/m³
Pul/Ltr
Pul/Ft³

=

Pulses/Gallon

=

Pulses/meter³

=

Pulses/Liter

=

Pulses/Ft³

KFactor

(K-Factor Value)

Numeric Entry

RateInt

(Rate time interval)

=

Sec

Second

=

Min

Hour

Day

Minute

=

Hour

=

Day

RateUnt

(Unit/interval=T)

GPT

=

Gallons/T

LB/T

=

Liquor Barrel/T

OB/T

=

Oil Barrel/T

AF/T

=

Acre Feet/T

ML/T

=

Million Liters/T

LPT

=

Liters/T

m³/T

=

Meters³/T

Ft³/T

=

Feet³/T

MG/T

=

Million
Gallons/T

MASS

Kg/T

=

Kilograms/T

Lb/T

=

Pounds/T

TotalUnt

(Totalizer Unit)

Gal

=

Gallons

LBL

=

Liquor Barrel

OBL

=

Oil Barrel

AFt

=

Acre Feet

MLt

=

Million Liters

LPT

=

Liters

m³

=

Meters³

Ft³

=

Feet³

MGa

=

Million
Gallons

MASS

Kgs

=

Kilograms

Lbs

=

Pounds

TotlMult

(Totalizer Multiplier)

× 1000

×100

×10

0.1

0.01

1

=

× 100

=

× 10

=

× 1

=

× 0.1

=

× 0.01

=

×1000

Spec Gr

(Specic Gravity)

Numeric Entry

Scale F

(Scale Factor)

Numeric Entry

SetTotl

(Set Total Value)

Numeric Entry

Cuto

(Low Flow Cuto)

Numeric Entry

Damping

(Display Damping)

Numeric Entry

Continued on

next page.

Menu item appears

only when MASS

units are selected.

DSY-PM-00028-EN-02Page 14 February 2017

Advanced ER-500, Advanced Menu (continued)

Continued from

previous page.

Menu Structure

PulsOut

(Pulse Output)

Disable
Enable

Fl=20mA

(Flow at 20 mA)

Numeric Entry

4-20Cal

(Calibrate 4-20)

NO

YES

4mA Out

(4 mA Output)

Numeric Entry

20mA Out

(20 mA Output)

Numeric Entry

4-20Tst

(4-20 mA Output)

Numeric Entry

Linear

(Linearization)

Lin Pts = Linear Points (2 to10)

Numeric Entry

Freq#1

(Frequency 1)

Numeric Entry

Coef#1

(Coecient 1)

Numeric Entry

Modbus

Disable

Enable

Modbus Address (1 to127)

SetPT1

(Setpoint 1)

Passwd

Numeric Entry

Password

HystSP1

(Hysteresis1)

Passwd

Numeric Entry

Password

TripSP1

(Trip On 1)

Passwd

High Low

Password

SetPT2

(Setpoint 2)

Passwd

Numeric Entry

Password

HystSP2

(Hysteresis2)

Passwd

Numeric Entry

Password

TripSP2

(Trip On 2)

Passwd

High Low

Password

BusAddr

Numeric Entry

Passwd

(Password)

Numeric Entry

RstPswd

(Reset Password)

Numeric Entry

Freq#(x)

(Frequency 2-10)

Numeric Entry

Coef#(x)

(Coecent 2-10)

Numeric Entry

DSY-PM-00028-EN-02 Page 15 February 2017

Clr G-T

(Clear Grand Total)

NO

YES

Programming

PROGRAMMING

OTE:N All of the following parameters appear in Extended Programming mode. Parameters with an asterisk (*) appear in

Programming mode as well.

Parameters

Select Display Function

The ER-500 monitor has three display selections— Flow, Grand Total and Test.

Flow

Use the Flow setting for normal operation of the monitor. In this mode, the display shows both the instantaneous flow rate
and current total simultaneously, see Figure 6.

2

Instantaneous

Flow Rate

Current

Total

Figure 6: Instantaneous flow rate and current total

Flow Grand Total

The Flow-GT setting forces the meter to alternate between the instantaneous flow and the grand total with roll-over counts,
see Figure 7.

The grand total is the accumulation of all the fluid that has gone through the meter since the last time the grand total was
cleared. This totalizer is in addition to the current total totalizer on the display and is always enabled.

In addition, the grand total screen displays the number of times the grand total has reached its maximum count (9,999,999)
and rolled over to zero.

1

Flow Rate

Units

Totalizer

Multiplier

Current Total Units

2

1

Roll-Overs

Total

Totalizer

Mode

Figure 7: Grand total

Roll-over
Indicator

Test

The Test setting places the monitor into a special diagnostic mode that shows the current input frequency and the
accumulated input counts. Figure 8 shows the layout for test mode values. The diagnostic mode makes it possible for you to
see precisely the frequency input the monitor is seeing and is very useful in troubleshooting and electrical noise detection.

At the Display prompt, press ENTER to view the current display setting. If the current display setting is correct, press ENTER to
advance to the next parameter. To change the display setting, press UP or RIGHT to scroll through the display options. Press
ENTER to save and advance to the KFacUnit parameter.

2

Input

Frequency

Figure 8: Test mode screen

1

Totalizer

Counts

DSY-PM-00028-EN-02Page 16 February 2017

Programming

Select Display's K-factor Unit*

At the KFacUnt prompt, press ENTER. The display shows the current K-factor unit. If the current selection is correct, press
ENTER to advance to the next parameter. To change the K-factor unit, press UP or RIGHT to scroll to the correct unit. The units
should match the units that the meter was calibrated in. Press ENTER to save and advance to the KFactor parameter.

Enter Flow Sensor's K-factor*

OTE:N The K-factor supplied with your meter or calculated from calibration data is needed to complete this step.

At the KFactor prompt, press ENTER. The most significant digit in the K-factor flashes. If the current K-factor is correct, press
ENTER to advance to the next parameter. To change the K-factor, press UP to increment the digit until it matches the meter’s

first K-factor digit. Press RIGHT to advance to the next digit. Repeat this process until all K-factor digits have been entered.
Press ENTER to save the K-factor and advance to the RateInt parameter.

OTE:N The number of digits available before and after the decimal point is determined by the bore size of the flow sensor

being used. The largest K-factors are associated with the smallest bore sizes. The maximum allowable K-factor is

99999.9. The minimum must be at least 1.000. If an out-of-range number is entered, the display flashes Limit and
refuses the entry.

Select Rate (Time) Interval*

At the RateInt prompt, press ENTER. The monitor flashes the current time interval. If the current selection is correct, press
ENTER to advance to the next parameter. To change to an alternate time interval, press UP or RIGHT to scroll to the correct
time interval. Press ENTER to save and advance to the RateUnt parameter.

Select Flow Rate Units*

At the RateUnt prompt, press ENTER. The monitor flashes the current rate unit. If the current selection is correct, press ENTER
to advance to the next parameter. To change to an alternate unit, press UP or RIGHT to scroll to the correct rate unit and press

ENTER to save and advance to the TotlUnt parameter.

Select Units of Measure for Total*

At the TotlUnt prompt, press ENTER. The monitor flashes the current total units. If the current selection is correct, press ENTER
to advance to the next parameter. To change to an alternate unit, press UP or RIGHT to scroll to the correct totalization unit.
Press ENTER to save and advance to the TotlMul parameter.

Select a Total Multiplier*

This parameter displays the accumulated flow total in multiples of 10. For example, if the optimum totalization unit is 1000
gallons, the unit total display increments by one digit for every 1000 gallons monitored. In Run mode, at 1000 gallons the total
monitor reads 1, at 3000 gallons, the total display reads 3. This feature eliminates having to look at a total, count the digits,
and mentally insert commas for each 1000 multiple.

At the TotlMul prompt, press ENTER . The monitor shows the current total multiplier. If the selection is correct, press ENTER to
advance to the next parameter. To change to an alternate multiplier, press UP or RIGHT to scroll to the correct multiplier unit
and press ENTER to and advance to the next parameter.

OTE:N If the RateUnt or TotlUnt parameter has been set to pounds or kilograms, the monitor advances to the Spec Gr

parameter. At any other setting, the monitor advances to Scale F. If pounds or kilograms have not been chosen, see

Enter a Scale Factor on page 18.

OTE:N If you are in Programming mode, the monitor advances to the PulsOut parameter.

See Totalizer Pulse Output* on page 19.

Enter a Specific Gravity Value*

Mass readings in the ER-500 monitor are not temperature or pressure compensated so it is best to enter the specific gravity
of the fluid as close to the system running temperature as possible. As liquids are essentially incompressible, pressure
compensation is not necessary for liquids.

At the Spec Gr prompt, press ENTER. The most significant digit of the current specific gravity flashes. If the current specific
gravity is correct, press ENTER to advance to the next parameter. To change to an alternate specific gravity, press UP to
increment the flashing digit until you reach the first digit of the new specific gravity. Press RIGHT to move to the next digit.
When all digits have been entered, press ENTER to save and advance to the Scale F parameter.

DSY-PM-00028-EN-02 Page 17 February 2017

Programming

Enter a Scale Factor

The scale factor is used to force a global span change. For example, in Run mode the display is reading a consistent three
percent below the expected values at all flow rates. Rather than changing the K-factor and linearization parameters
individually, the scale factor can be set to 1.03 to correct the readings. The range of scale factors is from 0.10…5.00. The
default scale factor is 1.00.

At the Scale F prompt, press ENTER. The first digit of the existing scale factor flashes. If the current selection is correct, press
ENTER to advance to the next parameter. To change to an alternate scale factor, press UP to increment the display digit until
it matches the first digit of the new scale factor. Press RIGHT to advance to the next digit. Repeat for all digits. Press ENTER to
save and advance to the SetTotl parameter.

OTE:N If the number you enter is out of range, the display flashes Limit and refuses the entry.

Preset Total

The preset total parameter sets the totalizer to a predetermined amount. The preset can have seven digits up to 8,888,888.
At the SetTotl prompt, press ENTER. The monitor displays the current set total. If the set total is correct, press RIGHT to

advance to the next parameter. To change the set total, press ENTER again. The first digit of the current preset total flashes.
Press UP to increment the display digit until it matches the first digit of the correct preset. Press RIGHT to advance to the next
digit. Repeat for all digits. Press ENTER to save and advance to the Cutoff parameter.

OTE:N If the number you enter is out of range the display, flashes Limit and refuses the entry.

Low Flow Cutoff

The flow cutoff shows low flow rates (that can be present when pumps are off and valves are closed) as zero flow on the flow
monitor. A typical value would be about five percent of the flow sensor’s maximum flow.

Enter the low flow cutoff as an actual flow value. For example, if the maximum flow rate for the flow sensor was 100 gpm, set
the low flow cutoff value to 5.0.

At the Cutoff prompt, press ENTER. The first digit of the current low flow cutoff flashes. If the current selection is correct,
press ENTER to advance to the next parameter. To change the low flow cutoff, press UP to increment the display digit until it
matches the first digit of the new low flow cutoff value. Press RIGHT to advance to the next digit. Repeat for all digits. Press

ENTER to save and advance to the Damping parameter.

OTE:N If the number you enter is out of range the display, flashes Limit and refuses the entry.

Damping Factor

The damping factor is increased to enhance the stability of the flow readings. Damping values are decreased to allow the
monitor to react faster to changing values of flow. This parameter can be any value between 0…99%, with 0 being the default.

At the Damping prompt, press ENTER. The most significant digit of the current setting flashes. If the current selection is
correct, press ENTER to advance to the next parameter. To change the damping value, press UP to increment the display digit
until it matches the new damping value. Press RIGHT to advance to the next digit. Press ENTER to save and advance to the

PulsOut parameter.

DSY-PM-00028-EN-02Page 18 February 2017

2.2

Internal

2.2

Programming

Totalizer Pulse Output*

The PulsOut parameter can be either enabled or disabled. When enabled, this output generates a fixed width 30 mS duration
pulse every time the least significant digit of the totalizer increments. The amplitude of the pulse is dependent on the voltage
level of the supply connected to the pulse output and is limited to a maximum 28V DC.

At the PulsOut prompt, press ENTER. The monitor displays the current setting. If the setting is correct, press ENTER to
advance to the next parameter. To change the parameter press UP or RIGHT to toggle between Disable and Enable. To save
your selection, press ENTER to advance to the Fl=20mA parameter.

The ER-500 monitor provides two types of totalizer pulses. The basic open drain FET output provides a ground referenced
output pulse that swings between about 0.7V DC and VCC, see Figure 9 on page 19.

TR_B

P1

TR_A

RS485 Gnd

Setpoint 1

Setpoint 2

Gnd

+

Freq. In

…10K

Pull-up

Resistor

Open Drain FET

Total Pulse Output

V

CC

Maximum

100 mA

4-20mA

Iso Total Pluse

Total Reset

Total Pluse

Signal Gnd

JP1

–

+

–

JP2

+

–

JP3

TB1

Pulse

Mag

High

Low

Input Total Pulse Signal

OC

Iso

Figure 9: Open drain connections

The isolated pulse output (ISO), see Figure 10, is again an open collector output with the emitter of the transistor connected
to the negative output terminal and is not referenced to ground. This output is optically isolated from the input signal for
systems that require a totally isolated output pulse.

…10K

Pull-up

Resistor

Isolated Output

TR_B

TR_A

RS485 Gnd

Setpoint 1

Setpoint 2

Freq. In

4-20mA

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

Gnd

+

–

+

–

+

–

Total Pulse

–V

V

CC

Maximum

100 mA

Figure 10: Opto-isolated open collector connections

P1

P1

JP1

JP1

Input Total Pulse Signal

Input Total Pulse Signal

Pulse

Mag

JP2

JP2

OC

Iso

JP3

JP3

High

Low

Internal

TB1

Both outputs have a maximum current capacity of 100 mA and require a pull-up resistor. The value of the pull-up resistor is
dependent on the supply voltage and the maximum current required by the load.

DSY-PM-00028-EN-02 Page 19 February 2017

Programming

Flow 20 mA*

When the display is operated using loop power, the flow rate that corresponds to 20 mA must be set. This setting normally
represents the maximum rate of the flow sensor connected to the display but other entries are possible.

At the Fl=20mA prompt, press ENTER. The first digit of the current setting flashes. If the current setting is correct, press ENTER
to advance to the next parameter. If the current setting requires a change, press UP to increment the display digit until it
matches the first digit of the required maximum flow value. Press RIGHT to advance to the next digit. Repeat for all of the
maximum flow at 20 mA digits. Press ENTER to save and advance to the 4-20Cal parameter.

OTE:N In Programming mode, the monitor advances to the Clr G-T parameter. See Clear Grand Total* on page 24.

4-20 mA Calibration

This setting allows the fine adjustment of the Digital to Analog Converter (DAC) that controls 4…20 mA output. The
4…20 mA output is calibrated at the factory and under most circumstances does not need to be adjusted. If the output needs
to be adjusted for any reason the 4…20 mA calibration procedure is used.

At the 4-20Cal prompt, press ENTER. The monitor displays No. If you do not need to complete the 4…20 mA calibration, press

ENTER to advance to the Linear parameter. See Linearization on page 21. To complete the 4…20 mA calibration, press UP or
RIGHT to change the display to Yes . Press ENTER to advance to the 4mA Out parameter.

4 mA Adjustment

To set the 4mA Out value, connect an ammeter in series with the loop power supply as shown in Figure 11. The 4 mA DAC
setting is typically 35…50. At the 4mA Out prompt, press UP to increase or RIGHT to decrease the current output while
monitoring the ammeter. When a steady 4 mA reading is established on the ammeter, press ENTER on the monitor to save
the output and advance to the 20mAOut parameter.

LOG

HOLD

FAST MAX MIN AVG

51000

0 0

MEM

AUTO

HM

HOLD MIN MAX REL

CANCEL SAVE NO

Hz % ms RANGE

nS

W

mV

ac+dc

V

ac+dc

mV

dB

V

dB

OFF

mA

A

µA

10A MAX

400mA

FUSED

FUSED

COM

VIEW MEM
CLEAR MEM

MS

°F

°C

CAT III

1000V

AutoHOLD FAST MIN MX LOGGING YES

SETUP

MANUAL

ac+dc

TEMPERATURE

TR_B

TR_A

RS485 Gnd

%

A

mA

µA

A
mA

ac+dc

µA

W

V

4-20 mA
Current Loop
(10…28V DC)

POWER

Setpoint 1

Setpoint 2

Freq. In

4-20mA

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

Gnd

+

–

+

–

+

–

SUPPLY

P1

JP1

Input Total Pulse Signal

Pulse

Mag

JP2

OC

Iso

JP3

High

Low

TB1

Figure 11: 4-20 mA calibration setup

20 mA Adjustment

The 20 mA adjustment is performed using the same procedure as the 4 mA adjustment.

4-20 mA Test

The ER-500 monitor contains a diagnostic routine that allows the simulation of mA output values between 4 …20 to check
output tracking. At the 4-20Tst prompt, the current flashes. Press UP to increase the simulated mA output in increments of
1 mA. Press RIGHT to decrease the mA output. The ammeter should track the simulated mA output. If a 4…20 mA test is not
necessary, press ENTER to advance to the Linear parameter.

OTE:N Press ENTER when the monitor is in test mode to exit the test mode and move on to the next

programming parameter.

DSY-PM-00028-EN-02Page 20 February 2017

Programming

Linearization

To increase accuracy, linearize the monitor. The linearization function accepts a maximum of ten points and requires
additional calibration data from the meter being used with the monitor. Typically, calibration information can be obtained
in three, five and ten points from the flow meter’s manufacturer. If linearization is not needed, press RIGHT to advance to
the Modbus parameter. See Modbus on page 22. To complete linearization, press ENTER at the Linear prompt. The monitor
advances to the Lin Pts parameter.

Number of Points

The Lin Pts value displays. If the number of points is set to 0, linearization is disabled. Press ENTER. The most significant digit
of the number of points entry begins to flash. The first number can be a 1 or a 0 only. Press UP to change the first digit. Press

RIGHT to move to the least significant digit.

OTE:N If the number you enter is out of range the, display flashes Limit and refuses the entry.

Press ENTER to advance to the Freq#1 prompt.

OTE:N If the number of linear points is set to 1, the ER-500 monitor assumes that you are entering the maximum frequency

and coefficient. Further, the meter assumes that the implied first point is at a frequency of 0 Hz and a coefficient of 0.

Frequency

At the Freq#1 prompt, press ENTER. The first digit of the first linear point’s frequency input flashes. Press UP to increment
the numerical values and RIGHT to change the position of the number being entered. When the frequency value input is
complete, press ENTER to save and advance to the Coef#1 parameter.

Coefficient

The coefficient is the value applied to the nominal K-factor to correct it to the exact K-factor for that point. The coefficient is
calculated by dividing the average (nominal) K-factor for that point by the actual K-factor for the flow meter.

Linear Coecient =

Nominal K-Factor

Actual K-Factor

At the Coef#1 prompt, press ENTER. The first digit of the coefficient flashes. Press UP to increment the digit, and RIGHT to
move to the next digit. When all digits have been entered, press ENTER to save and advance to the next frequency input.

Continue entering pairs of frequency and coefficient points until all data has been entered. Press ENTER to save and advance
to the Modbus parameter.

OTE:N The frequency values must be entered in ascending order. If a lower frequency value is entered after a higher value

the ER-500 monitor flashes Limit followed by the minimum frequency value acceptable to the display.

Example:

The following is actual data taken from a one inch turbine flow sensor calibrated with water.

Unit Under Test (UUT) Calibration In GPM

Actual

GPM

UUT

Frequency

Hz Counts/Gallon GPM % Rate

UUT Actual

K-factor

(Hz x 60)

Nominal K

Linear

Coefficient

Raw Error

50.02 755.900 906.72 49.72 1.0060 0.59

28.12 426.000 908.96 28.02 1.0035 0.35

15.80 240.500 913.29 15.82 0.9987 -0.13

8.88 135.800 917.57 8.93 0.9941 -0.59

4.95 75.100 910.30 4.94 1.0020 0.20
Nominal K (NK) 912.144 — —

In this example the linear coefficient has already been calculated by the calibration program so all that is required is to enter
five into the Lin Pts parameter and then enter, in order, the five frequency and linear coefficient data pairs.

DSY-PM-00028-EN-02 Page 21 February 2017

Programming

Modbus

The Modbus output parameter can be either enabled or disabled. When enabled, this output allows communications with the
ER-500 monitor using the Modbus RTU protocol. For additional information see Modbus Interface on page 27.

At the Modbus prompt, press ENTER. The current state of the Modbus output is shown. If the current state is correct, press
ENTER to advance to the next parameter. To change the modbus setting, press UP or RIGHT to toggle between states. When
the proper state displays, press ENTER to save and advance to the BusAddr parameter.

Bus Address

If the Modbus output is enabled, you must choose a valid Modbus address. Every device communicating over the RS485
communications bus using the Modbus protocol must have a unique bus address. Address values range from 0…127 with 0
being the default.

At the BusAddr prompt, press ENTER. The first digit of the address flashes. If the current setting is correct, press ENTER to
advance to the next parameter. To change the address, press UP to increment the display digit until it matches the first digit
of the new bus address. Press RIGHT to advance to the next digit. Repeat for all digits of the address. Press ENTER to save the
new address and advance to the SetPt 1 parameter.

Setpoints

Setpoints allow the meter to signal when a specific flow condition has been achieved. They are commonly used to indicate
high or low flow conditions that need attention. The ER-500 monitor has two open collector outputs controlled by the
setpoint function.

The setpoint transistors have the same current limitations and setup requirements as the totalizing pulse output transistors
described previously. See Figure 12 on page 23 for control output transistor connections.

Both setpoint 1 and setpoint 2 are configured using the same procedures, but the hysteresis and tripping conditions can be
different for each setpoint output.

OTE:N In most instances, the current capacity of an open collector transistor is not sufficient to operate old style counters

that relied on relay contact closures. When used with basic counting circuits, a solid-state relay is needed. See Figure

13 on page 23 for a connection example.

DSY-PM-00028-EN-02Page 22 February 2017

2.2

V

Minimum

Maximum

Hysteresis

Programming

Setpoint 1

The setpoint is the flow value at which the output transistor changes state. It is set using the same units as the rate units.

…10k

CC

Pull-up
Resistor

Open Collector

Control Output

1 and 2

100 mA

Maximum

RS485 Gnd

Setpoint 1

Setpoint 2

Freq. In

4-20mA

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

TR_B

TR_A

Gnd

+

–

+

–

+

–

P1

OUTPUT

1 2

Solid State

Relay

4 3

JP1

Input Total Pulse Signal

Pulse

Mag

High

Low

TB1

Internal

JP2

OC

Iso

JP3

INPUT

2.2 to 10k
Pull-up

Resistor

V

CC

100 mA

Maximum

Open Collector
Control Output

1 or 2

RS485 Gnd

Setpoint 1

Setpoint 2

Freq. In

4-20mA

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

TR_B

P1

TR_A

Gnd

+

JP1

Input Total Pulse Signal

–

Pulse

+

–

JP2

+

–

JP3

TB1

Mag

High

Low

Internal

OC

Iso

Figure 12: Setpoint output Figure 13: Typical solid state relay connections

At the SetPt 1 prompt, press ENTER. The most significant digit of the current setting flashes. If the current setting is correct,
press ENTER to advance to the next parameter. To change the current setting, press RIGHT to advance to the first digit of the
required set point value. Press UP to increment the digit until it matches the first number of the required set point. Repeat for
all the digits the set point. Press ENTER to save the new set point and advance to the HystSP1 parameter.

Hysteresis 1

Hysteresis is used to modify how the output transistor reacts around a setpoint by taking recent history into account.
Hysteresis prevents an output from turning on and off rapidly when the programmed flow rate is at or very near the setpoint.

For example, a low flow alarm is set to activate when the flow falls below a pre-programmed point. When the flow is reduced
to the setpoint, even minute changes of flow above the setpoint turns the output off, disabling the alarm. Without hysteresis,
if the flow rate fluctuates slightly above and below the setpoint, the output rapidly cycles between on and off states. See

Figure 14. The hysteresis value is set using the same units as the rate units.

At the HystSP1 prompt, press ENTER. The most significant digit of the current setting flashes. If the current setting is correct,
press ENTER to advance to the next parameter. To change the current setting, press RIGHT to advance to the first digit of the
required hysteresis value. When the correct place is reached, press UP to increment the digit until it matches the first number
of the required hysteresis. Press RIGHT to advance to the next digit of the required hysteresis value and press UP to increment
the display digit until it matches the next digit of the required hysteresis. Repeat this step for the all the digits of the hysteresis
and then press ENTER to save the new hysteresis and advance to the next parameter.

Flow

Output OFF

OFF Setpoint

ON Setpoint

Figure 14: Setpoint actions

Flow

Output ON

DSY-PM-00028-EN-02 Page 23 February 2017

Minimum

Maximum

(2 gpm)

Normally Open

Programming

Trip SP 1

The trip parameter can be set for either High or Lo. When set to high, the open collector transistor stops conducting and sends
the output high when the setpoint is reached. The output will not go low again until the flow rate falls below the setpoint
minus the hysteresis value. When set to low, the open collector transistor starts conducting and sends the output low when
the setpoint is reached. The output will not go high again until the flow rate exceeds the setpoint plus the hysteresis value.

For example, if the set point is 10 gpm, the hysteresis is set to 2 gpm and the trip setpoint is set to High (see Figure 15). When
the flow goes above 10 gpm the OC transistor stops conducting and the output goes high. The output stays high until the
flow rate drops below 8 gpm which is the setpoint (10 gpm) minus the hysteresis (2 gpm).

Flow

OFF (8 gpm)

Setpoint (10 gpm)

Output ON

Flow

Output OFF

Hysteresis

Figure 15: Setpoint example

At the TripSP1 prompt, press ENTER. The tripping condition setting is displayed. If the current setting is correct, press ENTER
to advance to the next parameter.

If the current setting requires a change, press RIGHT to advance to the alternate choice. Once the correct choice is displayed,
press ENTER to save the new trip condition and advance to the next parameter.

Clear Grand Total*

At the Clr G-T prompt, press ENTER. The flow monitor displays No. To clear the grand total press, UP or RIGHT to change from
No to Yes. Press ENTER to select Ye s and advance to the next parameter. The totalizer can also be reset using a hardware reset

as shown in Figure 16.

TR_B

P1

TR_A

RS485 Gnd

Setpoint 1

Setpoint 2

Gnd

+

Freq. In

JP1

Input Total Pulse Signal

–

Pulse

Mag

OC

Iso

High

Low

TB1

Pushbutton

Switch

4-20mA

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

+

–

JP2

+

–

JP3

Figure 16: Hardware reset

DSY-PM-00028-EN-02Page 24 February 2017

K-factors Explained

Password*

The password setting restricts access to the Programming and Extended Programming modes. Initially, the password is set to all
zeros and any user can modify the parameter settings. To change the password, press ENTER at the Passwd prompt. The first
digit flashes. Press UP to increment the digit and RIGHT to advance to the next digit. After entering all digits, press ENTER to
store the password and advance to RstPswd. The new password is now required to enter either programming mode. With this
password set, any user is able to reset the stored totals on the monitor.

Reset Password*

The reset password parameter restricts resetting the totals on the monitor. The Passwd must also be set to restrict the total
reset. Initially, the password is set to all zeros and any user can reset the stored totals on the monitor. To change the password,
press ENTER at the RstPswd prompt. The first digit flashes. Press UP to increment the digit and RIGHT to advance to the next
digit. After entering all digits, press ENTER to store the password and return to the Fluid parameter. The reset password is now
required to reset the totals on the monitor.

OTE:N Entering a password in the Passwd screen and leaving the password blank in the RstPswd screen allows for total resets

(not requiring a password), but restricts programming modification.

KFACTORS EXPLAINED

The K-factor (with regards to flow) is the number of pulses that must be accumulated to equal a particular volume of fluid. You
can think of each pulse as representing a small fraction of the totalizing unit.

An example might be a K-factor of 1000 (pulses per gallon). This means that if you were counting pulses, when the count total
reached 1000, you would have accumulated 1 gallon of liquid. Using the same reasoning, each individual pulse represents an
accumulation of 1/1000 of a gallon. This relationship is independent of the time it takes to accumulate the counts.

The frequency aspect of K-factors is a little more confusing because it also involves the flow rate. The same K-factor number,
with a time frame added, can be converted into a flow rate. If you accumulated 1000 counts (one gallon) in one minute, then
your flow rate would be 1 gpm. The output frequency, in Hz, is found simply by dividing the number of counts (1000) by the
number of seconds (60) to get the output frequency.

1000 ÷ 60 = 16.6666 Hz. If you were looking at the pulse output on a frequency counter, an output frequency of 16.666 Hz
would be equal to 1 gpm. If the frequency counter registered 33.333 Hz (2 × 16.666 Hz), then the flow rate would be 2 gpm.

Finally, if the flow rate is 2 gpm, then the accumulation of 1000 counts would take place in 30 seconds because the flow rate,
and hence the speed that the 1000 counts is accumulated, is twice as great.

Calculating K-factors

Many styles of flow meters are capable of measuring flow in a wide range of pipe sizes. Because the pipe size and volumetric
units the meter will be used on vary, it may not possible to provide a discrete K-factor. In the event that a discrete K-factor is
not supplied then the velocity range of the meter is usually provided along with a maximum frequency output.

The most basic K-factor calculation requires that an accurate flow rate and the output frequency associated with that flow
rate be known.

Example 1:

Known values are:
Frequency = 700 Hz
Flow Rate = 48 GPM

700 Hz × 60 sec = 42,000 pulses per min

42,000 pulses per min

K-factor

= =

48 gpm

875 pulses per gallon

DSY-PM-00028-EN-02 Page 25 February 2017

 

A

A

2

7

ft

= 0.384 gallons

231 in

K-

42,000 pulses per min

99.1 gpm

n

Modbus Interface

Example 2:

Known values are:
Full Scale Flow Rate = 85 gpm
Full Scale Output Frequency = 650 Hz

650 Hz × 60 sec = 39,000 pulses per min

K-factor 458.82 pulses per gallon= =

39,000 pulses per min

85 gpm

The calculation is a little more complex if velocity is used because you first must convert the velocity into a volumetric flow
rate to be able to compute a K-factor.

To convert a velocity into a volumetric flow, the velocity measurement and an accurate measurement of the inside diameter
of the pipe must be known. Also needed is the fact that 1 US gallon of liquid is equal to 231 cubic inches.

Example 3:

Known values are:
Velocity = 4.3 ft/sec
Inside Diameter of Pipe = 3.068 in.

Find the area of the pipe cross section.

2

πr

rea =

3.068

rea

 

= π = π x

 

2

2.35 = 7.39 in

2

Find the volume in 1 ft of travel.

2

.3 in2 x 12 in (1 ft) =

88.71in

What portion of a gallon does 1 ft of travel represent?

3

88.71 in

3

So for every foot of fluid travel 0.384 gallons will pass.

What is the flow rate in gpm at 4.3 ft/sec?

0.384 gallons × 4.3 FPS × 60 sec (1 min) = 99.1 gpm
Now that the volumetric flow rate is known, all that is needed is an output frequency to determine the K-factor.
Known values are:
Frequency = 700 Hz (By measurement)
Flow Rate = 99.1 gpm (By calculation)

700 Hz × 60 sec = 42,000 pulses per gallon

factor

==

423.9 pulses per gallo

DSY-PM-00028-EN-02Page 26 February 2017

Modbus Interface

MODBUS INTERFACE

A subset of the standard Modbus commands is implemented to provide access into the data and status of the ER-500
monitor. The following Modbus commands are implemented:

Command Description

01 Read Coils

03 Read Holding Registers

05 Force Single Coil

Type Bits Bytes Modbus Registers

Long Integer
Single Precision IEEE754

Modbus Register / Word Ordering

Each Modbus holding register represents a 16-bit integer value (2 bytes). The official Modbus standard defines Modbus as a
‘big-endian’ protocol where the most significant byte of a 16-bit value is sent before the least significant byte. For example,
the 16-bit hex value of ‘1234’ is transferred as ‘12’ ‘34’.

Beyond 16-bit values, the protocol itself does not specify how 32-bit (or larger) numbers that span over multiple registers
should be handled. It is very common to transfer 32-bit values as pairs of two consecutive 16-bit registers in little-endian word
order. For example, the 32-bit hex value of ‘12345678’ is transferred as ‘56’ ‘78’ ‘12’ ‘34’. Notice the Register Bytes are still sent in
big-endian order per the Modbus protocol, but the Registers are sent in little-endian order.

Other manufacturers store and transfer the Modbus Registers in big-endian word order. For example, the 32-bit hex value
of ‘12345678’ is transferred as ‘12’ ‘34’ ‘56’ ‘78’. It does not matter which order the words are sent, as long as the receiving
device knows which way to expect it. Since word order is a common problem between devices, many Modbus master
devices have a configuration setting for interpreting data (over multiple registers) as ‘little-endian’ or ‘big-endian’ word order.
This is also referred to as swapped or word swapped values and allows the master device to work with slave devices from
different manufacturers.

If the endianness is not a configurable option within the Modbus master device, it’s important to make sure it matches
the slave endianess for proper data interpretation. The ER-500 monitor actually provides two Modbus register maps to
accommodate both formats. This is useful in applications where the Modbus master cannot be configured for endianness.

32 4 2

32 4 2

Register Mappings

Data Component

Name

Spare 40100…40101 40200…40201 —
Flow Rate 40102…40103 40202…40203
Spare 40104…40105 40204…40205
Positive Totalizer 40106…40107 40206…40207
Grand Total Totalizer 40108…40109 40208…40209
Battery Voltage 40110…40111 40210…40211 x.xx
Spare 40112…40113 40212…40213 —

Long Integer

Format

For reference: If the ER-500 totalizer = 12345678 hex
Register 40106 would contain 5678 hex (Word Low)
Register 40107 would contain 1234 hex (Word High)

MODBUS Registers

Single Precision

Floating Point Format

DSY-PM-00028-EN-02 Page 27 February 2017

Available Units

Gallons, Liters, MGallons, Cubic Feet, Cubic Meters, Acre

Feet, Oil Barrel, Liquid Barrel, Feet, Meters, Lb, Kg, BTU,

MBTU, MMBTU, TON

Second, Minute, Hour, Day

Per

Modbus Interface

Data Component

Name

Spare 40600…40601 40700…40701 –
Flow Rate 40602…40603 40702…40703

Spare 40604…40605 40704…40705

Positive Totalizer 40606…40607 40706…40707

Grand Total Totalizer 40608…40609 40708…40709

Battery Voltage 40610…40611 40710…40711 x.xx
Spare 40612…40613 40712…40713

Long Integer

MODBUS Registers

Format

Single Precision

Floating Point Format

Available Units

Gallons, Liters, MGallons, Cubic Feet, Cubic Meters, Acre

Feet, Oil Barrel, Liquid Barrel, Feet, Meters, Lb, Kg, BTU,

MBTU, MMBTU, TON

Second, Minute, Hour, Day

For reference: If the ER-500 totalizer = 12345678 hex
Register 40606 would contain 1234 hex (Word High)
Register 40607 would contain 5678 hex (Word Low)

Modbus Coil Description Modbus Coil Notes

Reset Running Totalizer 1

Reset Grand Totalizer 2

—

Alarm Setpoint 1 9 0 = Setpoint OFF, 1 = Setpoint ON
Alarm Setpoint 2 10 0 = Setpoint OFF, 1 = Setpoint ON

—

3…8 Spares

11…16 Spares

Forcing this coil ON will reset the running totalizer. After reset, the coil
automatically returns to the OFF state.

Forcing this coil ON will reset both the running totalizer and the grand totalizer.
After reset, the coil automatically returns to the OFF state.

Opcode 01 - Read Coil Status

This opcode returns the state of the alarm coils. The following Coils are defined:

Per

Coil # Description

9 Alarm Setpoint 1

10 Alarm Setpoint 2

11 and up Spare

Command: <addr><01><00><08><00><02><crc-16>
Reply: <addr><01><01><0x><crc-16>

Opcode 03 - Read Holding Registers

This opcode returns the input holding registers, such as flow rate or totalizer.

OTE:N Each value must be requested individually. Return of a block of registers is not implemented at this time.
Example requesting flow rate in floating point format.
Command: <addr><03><00><C9><00><02><crc-16>

Reply: <addr><03><02><data><data><crc-16>

Opcode 05 - Force Single Coil

This opcode sets the state of a single coil (digital output). The following Coil Registers are defined:

Coil # Description

1 Reset Totalizer
2 Grand Totals

3 and up Spares

The transition of coil from 0 to 1 will initiate function. This bit is auto reset to 0, so there is no need to set it to 0 after a totalizer
reset command.

Command: <addr><05><00><00><FF><00><crc-16>
Reply: <addr><05><00><00><FF><00><crc-16>

DSY-PM-00028-EN-02Page 28 February 2017

Battery Replacement

BATTERY REPLACEMENT

Battery powered monitors use a single 3.6V DC D size, lithium battery. When replacement is necessary, use a clean fresh
battery to ensure continued trouble-free operation.

Replacement Batteries

Manufacturer Part Number

Badger Meter B300028

Xeno S11-0205-10-03

Tadiran TL-5930/F

2. Unscrew the four captive screws on the front panel to gain access to the battery (see Figure 17).

J1

KB/Display

TR_B

P1

TR_A

RS485 Gnd

2

1

Setpoint 1

Setpoint 2

Gnd

Unscrew

Captive Screws

+ –

+

Freq. In

JP1

Input Total Pulse Signal

–

Pulse

Mag

+

4-20mA

–

JP2

OC

+

Iso

Iso Total Pluse

–

JP3

High

Total Reset

P2

OC Total Pluse

Low

Signal Gnd

TB1

Figure 17: Opening the

3. Press the tab on the battery connector to release it from the circuit board (see Figure 18).

Press

Battery

REPLACE BATTER WITH

XEON S11-0205-10-03

OR TADIRAN TL-5930/F ONLY

P2

+ –

J1

KB/Display

WARNING- To reduce the risk of ignition

of a ammable atmosphere, batteries

must only be changed in an area known

to be nonammable.

RS485 Gnd

4-20 mA

ISO Total Pulse

Total Reset

OC Total Pulse

Signal Gnd

TR-A
TR-B

RS485 Gnd

Setpoint 1

Setpoint 1

Setpoint 2

Setpoint 2

Gnd

Freq. In

Freq. In

4-20mA

Iso Total Pluse

Total Reset

OC Total Pluse

Signal Gnd

Release

Tab

TR_B

P1

TR_A

Gnd

+

+

JP1

Input Total Pulse Signal

–

Pulse

-

Mag

+

+

–

JP2

-

OC

+

+

Iso

–

-

JP3

High

Low

TB1

Connector

Connector

Figure 18: Battery connection release.

4. Remove the old battery and replace it with new one.

5. Re-fasten the front panel screws.

Slide

Away

DSY-PM-00028-EN-02 Page 29 February 2017

COM

Specications

SPECIFICATIONS

Simultaneously shows Rate and Total
5 x 7 Dot matrix LCD, STN fluid

LCD

Annunciators

Power

Inputs

Outputs

Safety
Certifications

Entity Parameters

EMC 2004/108/EC
Accuracy 0.05%
Response Time 1…100 seconds response to a step change input, user adjustable
Environmental

Limits
Materials Polycarbonate, stainless steel, polyurethane, thermoplastic elastomer, acrylic
Enclosure Ratings NEMA 4X/IP 66

6 Digit rate, 0.5 inch (12.7 mm) numeric
7 Digit total, 0.5 inch (12.7 mm) numeric
Engineering unit labels 0.34 inch (8.6 mm)

Alarm 1(1), Alarm 2 (2), Battery Level ( ), RS485 Communications (

Battery 3.6V DC lithium “D Cell” gives up to 6 years of service life

4…20 mA, two wire, 25 mA limit, reverse polarity protected, 7 V DC loop loss

Loop

Auto switching between internal battery and external loop power; includes isolation between
loop power and other I/O

Frequency Range 1…3500 Hz
Frequency Accuracy ±0.1%

Magnetic Pickup

Over Voltage Protection 28V DC

Trigger Sensitivity

30 mVp-p (High) or 60 mVp-p (Low) - (selected by circuit board

jumper)
Amplified Pulse Direct connection to amplified signal (pre-amp output from sensor)
Analog 4…20 mA 4…20 mA, two-wire current loop 25 mA current limit

One pulse for each Least Significant Digit (LSD) increment of the totalizer

Totalizing Pulse

Pulse Type
(selected by circuit board
jumper)

Maximum Voltage 28V DC

Opto-isolated (Iso) open collector transistor

Non-isolated open drain FET

Maximum Current Capacity 100 mA
Maximum Output

Frequency

16 Hz

Pulse Width 30 mS fixed

Open collector transistor Adjustable flow rate with programmable

dead band and phase.
Status Alarms

(Advanced Only)

Type

Maximum Voltage 28V DC
Maximum Current 100 mA
Pull-Up Resistor: External required (2.2 K ohm minimum, 10 K ohm maximum)

Modbus
(Advanced Only)

Data Configuration
and Protection

Modbus RTU over RS485, 127 addressable units / 2-wire network, 9600 baud, long integer and
single precision IEEE754 formats; retrieve: flow rate, job totalizer, grand totalizer, alarm status and
battery level; write: reset job totalizer, reset grand totalizer

Two 4-digit user selectable passwords; level one password enables Job Total reset only, level
two password enables all configuration and totalizer reset functions (Not Applicable on solar
powered units)

Class I Division 1, Groups C, D; Class II, Division 1 Groups E, F, G; Class III for US and Canada. Complies with UL 913 and
CSA C22.2 No. 157-92

4…20mA Loop V
Pulse Output V
Reset Input V
RS485 V

= 28V DC I

max

= 28V DC I

max

= 5V DC I

max

= 10V DC I

max

= 26 mA Ci = 0.5 F Li = 0 mH

max

= 100 mA Ci = 0 F Li = 0 mH

max

= 5 mA Ci = 0 F Li = 0 mH

max

= 60 mA Ci = 0 F Li = 0 mH

max

Sensor Input Voc = 2.5 V Isc = 1.8 mA C = 1.5 F La = 1.65 H

–22…158° F (–30…70° C); 0…90% humidity, non-condensing;

)

DSY-PM-00028-EN-02Page 30 February 2017

MODEL NUMBERS

DIMENSIONS

Model Numbers

ER-500

A = Advanced
S = Standard

P2

+ –

A B C

5.0 in. (127.0 mm) 4.5 in. (114.3 mm) 2.6 in. (66.0 mm)

TROUBLESHOOTING GUIDE

Trouble Remedy

B

KB/Display

C

J1

TR_B

P1

TR_A

RS485 Gnd

2

1

2

1

Setpoint 1

Setpoint 2

Gnd

+

Freq. In

JP1

Input Total Pulse Signal

–

Pulse

Mag

Iso Total Pluse

OC Total Pluse

Total Reset

Signal Gnd

+

4-20mA

–

JP2

OC

+

Iso

–

JP3

High

Low

TB1

A

Battery Check battery voltage. Should be 3.6 V DC. If the input is 3.4V DC or lower, replace the battery.

No LCD

Display

Loop
power

No Rate or Total
Displayed

Flow Rate Display
Interprets Reading
Constantly

Flow Rate Indication
Erratic

Check 4…20 mA input. Voltage must be within the minimum and maximum supply voltage and
capable of supplying enough current to run the display. The input voltage is checked “across” or
in parallel with the 4…20 mA terminals and current is checked with the ammeter in series with
the 4…20 mA output.

Check connection from meter's transmitter to display input terminals.
Check turbine meter rotor for debris. Rotor should spin freely.
Check programming of flow monitor.

This is usually an indication of external noise. Keep all AC wires separate from DC wires.
Check for large motors close to the meter pickup.
Check for radio antenna in close proximity.

This usually indicates a weak signal. Replace pickup and/or check all connections.
Check for correct factor.
Check that the ILR transmitters meter size selection switch is set to the correct size.

DSY-PM-00028-EN-02 Page 31 February 2017

NOTES ON CABLE ENTRY

NOTES ON CONTROL EQUIPMENT

WITH RESPECT TO EARTH.

1. CONTROL EQUIPMENT MUST NOT USE OR GENERATE MORE THAN 250 V,

1. ALL CABLE ENTRIES INTO THE ENCLOSURE MUST BE BROUGHT

THROUGH SUITABLY SIZED UL & CSA CERTIFIED LIQUID TIGHT
STRAIGHT THRU FITTINGS

NOTES ON FLOW SENSOR

1. INTERCONNECTING CABLE CAPACITANCE AND INDUCTANCE, PLUS THE

CAPACITANCE AND INDUCTANCE OF THE MAGNETIC PICKUP, MUST BE LESS
THAN OR EQUAL TO THE CAPACITANCE(Ca) AND THE INDUCTANCE(La) "TURBINE
INPUT" ENTITY PARAMETERS MARKED ON THE B3000 MONITOR AND TABLE 2.

Control Drawing

CONTROL DRAWING





V Max

I Max

Ci
Li

4-20mA Loop

28 Vdc

26mA

0.5µF

0.0mH

Pulse Output

28 Vdc

100mA

0.0µF

0.0mH

Reset Input RS485

5 Vdc

10 Vdc

5mA

60mA

0.0µF

0.0µF

0.0mH

0.0mH

Turbine Input

Voc = 3.5V
Isc = 3.6mA

Ca = 15µF

La = 1.65H

26 Vdc MAX.+

PULSE INPUT

20-35 VDC

NON-HAZARDOUS LOCATION

RTU/PLC

-

GND.

1 3

4-20mA

2 4

R LOAD

MTL SAFETY BARRIER

MODEL 7787+

1 3

2 4

* 0.1 mA @ .7 VOLT DROP

MODEL 7706+

HAZARDOUS LOCATION

(CLASSIFIED)

CLASS I, DIV 1

GROUP C & D

CLASS I, ZONE 0, IIB

CLASS II, DIV 1

GROUP E, F & G

SET POINT &

TOTAL PULSE 1/F

4-20mA 1/F



10 FT. TO MAX. 100 FT.

HOST

R5485

MODEL 7766 Pac

1 3

2 4

R5485 1/4

HAZARDOUS LOCATION

NOTES ON BARRIERS:

1. SELECTED BARRIERS MUST BE CERTIFIED AS

INTRINSICALLY SAFE FOR THE APPLICATION AND HAVE Voc

NOT EXCEEDING Vmax AND Isc NOT EXCEEDING Imax
CAPACITIANCE VALUE SHALL BE AS SHOWN IN TABLE 1.

2. INTERCONNECTING CABLE CAPACITANCE AND INDUCTANCE, PLUS

THE CAPACITANCE AND INDUCTANCE OF THE INTRINSICALLY SAFE

EQUIPMENT, MUST BE LESS THAN OR EQUAL TO THE CAPACITANCE

3. MAY BE IN DIVISION 2 LOCATION IF SO APPROVED

4. BARRIERS MUST BE INSTALLED IN ACCORDANCE WITH BARRIER

MANUFACTURER'S CONTROL DRAWING, CANADIAN ELECTRICAL CODE

PART 1, SEC. 18 AND APPENDIX F, ARTICLE 500 OF THE NEC, OR
OTHER LOCAL CODES.

5. WHEN SELECTING CABLE FOR CONNECTION TO

TURBINE METER, USE CABLE WITH THE FOLLOWING

Figure 19: Control drawing

DSY-PM-00028-EN-02Page 32 February 2017

















 



 

  

NOTES ON CABLE ENTRY

NOTES ON CONTROL EQUIPMENT

WITH RESPECT TO EARTH.

1. CONTROL EQUIPMENT MUST NOT USE OR GENERATE MORE THAN 250 V,

Li + Lc

Ci + Cc

Imax

Vmax

IS EQUIPMENT

BARRIER

Voc

Isc
Ca

>

>

TABLE 1:

<

< La

1. ALL CABLE ENTRIES INTO THE ENCLOSURE MUST BE BROUGHT

THROUGH SUITABLY SIZED UL & CSA CERTIFIED LIQUID TIGHT
STRAIGHT THRU FITTINGS

NOTES ON FLOW SENSOR

1. INTERCONNECTING CABLE CAPACITANCE AND INDUCTANCE, PLUS THE

CAPACITANCE AND INDUCTANCE OF THE MAGNETIC PICKUP, MUST BE LESS
THAN OR EQUAL TO THE CAPACITANCE(Ca) AND THE INDUCTANCE(La) "TURBINE
INPUT" ENTITY PARAMETERS MARKED ON THE B3000 MONITOR AND TABLE 2.

ADVANCE PRINT

ER#

19828

ENG.

DN DATE:

3/30/16

Control Drawing

DSY-PM-00028-EN-02 Page 33 February 2017

Display, ER-500 Advanced

INTENTIONAL BLANK PAGE

DSY-PM-00028-EN-02Page 34 February 2017

INTENTIONAL BLANK PAGE

Programming Manual

DSY-PM-00028-EN-02 Page 35 February 2017

Display, ER-500 Advanced

Control. Manage. Optimize.

Trademarks appearing in this document are the property of their respective entities. Due to continuous research, product improvements and enhancements, Badger Meter reserves
the right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists. © 2017 Badger Meter, Inc. All rights reserved.

www.badgermeter.com

The Americas | Badger Meter | 4545 West Brown Deer Rd | PO Box 245036 | Milwaukee, WI 53224-9536 | 800-876-3837 | 414-355-0400
México | Badger Meter de las Americas, S.A. de C.V. | Pedro Luis Ogazón N°32 | Esq. Angelina N°24 | Colonia Guadalupe Inn | CP 01050 | México, DF | México | [phone]
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